Allelys, THLG member for the UK, were contracted to install fifteen components for the Rassau project. These components, when combined, form a synchronous condenser, which will add inertia and frequency stability to the power grid in the UK. This was a pivotal project for the industry, with the synchronous condenser being the first to go live within the UK.
The components, with weights ranging from 7.5te to 200te, were scheduled to be installed into a generator hall in South Wales. The confined space within the hall added an extra layer of complexity to the project and required a bespoke engineering solution to be designed.
The first task was to deliver, lift and install five containers to a raised foundation. A 200te mobile crane and specialist lifting tackle was used to lift each unit to its final position.
An 11.5te auxiliary transformer was the second component to be received and was installed on site, again using a 200te mobile crane. The third unit was a 73.5te step up transformer, which Allelys received at Southampton docks onto a 6 axle MPA low loader trailer and transported to site. It was then lifted and positioned onto its foundation using a 500te mobile crane.
A 450te hydraulic gantry system was then mobilised on site to lift, propel and position the 9.5te pony motor, utilising 2 jacks, followed by a 62.5te fly wheel, utilising 4 jacks. Due to the confined space, it was then necessary to complete a partial de mobilisation of the equipment by removing all of the jacks, rigging and load spreading mats, enabling a 60/80 Versa Lift to install the 7.5te oil skid and 10te cooler unit.
The outdoor cooler was the next to be delivered and installed. At 12 meters in length and limited lifting options, Allelys designed a bespoke lifting solution and utilised a 100te mobile crane to ensure the job was completed without incident.
For the next two components, the 450te hydraulic gantry system was mobilised once again.
Allelys received the 200te generator at Newport, transported it to site on a 18 axle flat top trailer, where it needed to be transhipped onto SPMT due to limited space. A 100te mobile crane was then used to lift the final piece, a 20te cover onto the generator prior to the complete component being manoeuvred into the generator building.
The SPMT was able to transport the generator around the tight corners, negotiate a downhill section of site road and reverse inside the generator building ready to be lifted.
“The confined space within the generator hall provided an additional challenge with this project. The team worked to engineer a solution to install the components in a particular order by using a range of specialist equipment,” explains Anthony Callachan, Project Manager at Allelys.
“Having to install the generator with the cover fitted brought extra challenges to the project team, as the generator had been designed so that the cover was fitted post-installation to its foundation. To overcome this we engineered, fabricated and tested bespoke lift links that would allow the generator to be lifted with the cover fitted”.
In addition to the transportation and installation, the Allelys team provided full engineering support and project management throughout the project.
